U.S. patent application number 15/789230 was filed with the patent office on 2018-03-01 for knitted shoe components and methods of making the same.
The applicant listed for this patent is Knitmasters, LLC. Invention is credited to Juan Aristizabal, Jeffrey W. Bruner.
Application Number | 20180055145 15/789230 |
Document ID | / |
Family ID | 52682944 |
Filed Date | 2018-03-01 |
United States Patent
Application |
20180055145 |
Kind Code |
A1 |
Aristizabal; Juan ; et
al. |
March 1, 2018 |
KNITTED SHOE COMPONENTS AND METHODS OF MAKING THE SAME
Abstract
In one aspect, methods of making a knitted shoe component are
described herein. In some embodiments, a method comprises knitting
one or more fibers to form a toe portion; knitting one or more
fibers to form a first wing portion; and knitting one or more
fibers to form a second wing portion. The first and second wing
portions extend from the toe portion and are knittingly connected
to the toe portion. The method further comprises reducing the
lateral separation between the first and second wing portions from
an initial separation distance to a knitting separation distance
such that the wing portions can be knitted together to form a
seamless heel portion of the shoe component, including using a
series of stitch transfer, racking, and knitting steps.
Inventors: |
Aristizabal; Juan;
(Greensboro, NC) ; Bruner; Jeffrey W.;
(Greensboro, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Knitmasters, LLC |
Colfax |
NC |
US |
|
|
Family ID: |
52682944 |
Appl. No.: |
15/789230 |
Filed: |
October 20, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15119411 |
Aug 17, 2016 |
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PCT/US2015/018796 |
Mar 4, 2015 |
|
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15789230 |
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61947793 |
Mar 4, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A43B 5/02 20130101; A43B
5/08 20130101; A43B 23/07 20130101; D04B 1/108 20130101; D10B
2501/043 20130101; A43B 5/06 20130101; D10B 2403/0332 20130101;
A43B 5/002 20130101; A43B 23/0205 20130101; A43B 23/0245 20130101;
D04B 1/24 20130101; A43B 23/042 20130101; A43B 13/38 20130101; D04B
1/106 20130101; A43B 3/02 20130101; A43B 15/00 20130101 |
International
Class: |
A43B 23/02 20060101
A43B023/02; A43B 5/02 20060101 A43B005/02; A43B 23/04 20060101
A43B023/04; A43B 3/02 20060101 A43B003/02; A43B 5/00 20060101
A43B005/00; A43B 23/07 20060101 A43B023/07; D04B 1/24 20060101
D04B001/24; A43B 5/08 20060101 A43B005/08; A43B 13/38 20060101
A43B013/38; A43B 15/00 20060101 A43B015/00; A43B 5/06 20060101
A43B005/06 |
Claims
1. A knitted shoe component comprising: a toe portion; a first wing
portion extending from the toe portion and knittingly joined to the
toe portion; a second wing portion extending from the toe portion
and knittingly joined to the toe portion; and a heel portion,
wherein the first wing portion and the second wing portion are
knittingly joined to one another at the heel portion.
2. The knitted shoe component of claim 1 further comprising: an
insole portion extending from the heel portion and knittingly
joined to the heel portion.
3. The knitted shoe component of claim 1, wherein the knitted shoe
component is a seamless component.
4. The knitted shoe component of claim 1, wherein the knitted shoe
component comprises a welt in the heel portion.
5. The knitted shoe component of claim 1, wherein the knitted shoe
component comprises a first welt in the toe portion and a second
welt in the heel portion.
6. The knitted shoe component of claim 1, wherein the knitted shoe
component has a knit structure differing from a circular knitting
knit structure.
7. The knitted shoe component of claim 1, wherein: the knitted shoe
component comprises at least a first region and a second region;
and the first region and the second region exhibit differing
relative rigidity, elasticity, support, softness, cushioning,
compression, breathability, weight, density, color, water wicking
ability, or water resistance.
8. The knitted shoe component of claim 1, wherein: the knitted shoe
component comprises one or more relatively soft regions and one or
more relatively abrasion resistant regions; the soft region is
located in the interior of the knitted shoe component, relative to
a foot of a wearer; and the abrasion resistant region is located on
the exterior of the knitted shoe component, relative to the foot of
the wearer.
9. The knitted shoe component of claim 1, wherein the knitted shoe
component does not have a uniform or substantially uniform
thickness.
10. The knitted shoe component of claim 9, wherein the knitted shoe
component defines contours or ridges.
11. The knitted shoe component of claim 1, wherein the knitted shoe
component is a shoe upper.
12. The knitted shoe component of claim 11 further comprising a
plurality of eyelets integral with the first wing portion, the
second wing portion, or both.
13. The knitted shoe component of claim 1, wherein the knitted shoe
component is an interior lining of a shoe.
14. The knitted shoe component of claim 1, wherein the knitted shoe
component is formed from knitted fibers, filaments, or yarns.
15. The knitted shoe component of claim 14, wherein the fibers,
filaments, or yarns are coated with a fluorocarbon.
16. The knitted shoe component of claim 14, wherein the fibers,
filaments, or yarns comprise one or more additives selected from
polymer additives, thermally conductive additives, ceramic
additives, metal additives, carbon fibers, carbon nanotubes,
graphite nanoplatelets, thermochromic pigments, photochromic
pigments, dye materials, antimicrobial materials, antifungal
materials, or a combination thereof.
17. The knitted shoe component of claim 14, wherein the fibers,
filaments, or yarns comprise a synthetic material selected from the
group consisting of a polyamide, polyester, polyethylene,
polypropylene, polybutylene, polyolefin, and polyacrylic, or a
natural material selected from the group consisting of cotton,
wool, silk, and cellulose.
18. A shoe comprising: the knitted shoe component of claim 1; and
one or more additional shoe components attached to the knitted shoe
component.
19. The shoe of claim 18, wherein the one or more additional shoe
components comprises a tongue component.
20. The shoe of claim 18, wherein the one or more additional shoe
components comprises a sole component.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application
Ser. No. 15/119,411, filed on Aug. 17, 2016, which is a U.S.
national stage application under 35 U.S.C. .sctn. 371 of
International Application No. PCT/US2015/018796, filed on Mar. 4,
2015, which claims priority pursuant to 35 U.S.C. .sctn. 119 to
U.S. Provisional Patent Application Ser. No. 61/947,793, filed on
Mar. 4, 2014, each of which is hereby incorporated by reference
herein its entirety.
FIELD
[0002] This invention relates to knitted shoe components and, in
particular, to knitted shoe components having a seamless
construction and methods of making the same.
BACKGROUND
[0003] Textiles and fabrics have been used to form various
components or portions of shoes and other footwear, including shoe
uppers. However, some prior uses of textiles and/or fabrics to faun
a shoe upper require stitching of the textiles and/or fabrics to
provide a shaped, three-dimensional component. Such
three-dimensional components thus include seams. The presence of
seams in a shoe upper can reduce the comfort and/or performance of
the shoe. Further, the need to stitch portions of textiles and/or
fabrics together to form shoe components can substantially reduce
the efficiency and/or increase the cost of manufacturing the
components.
[0004] Therefore, there exists a need for improved shoe components
and improved methods of making shoe components.
SUMMARY
[0005] In one aspect, methods of making a knitted shoe component
are described herein which, in some cases, can provide one or more
advantages compared to other methods. For example, in some
instances, a method of making a knitted shoe component described
herein can provide a knitted shoe component such as a knitted shoe
upper that is free of seams, such as seams formed by a sewing or
linking process. In particular, a method described herein can be
used to form a seamless, three-dimensional knitted shoe component
from two or more widely separated portions of a knitted fabric,
including portions separated by a distance larger than the maximum
racking distance of a knitting machine used to form the fabric.
Moreover, a method described herein can provide a knitted shoe
component in a more efficient and/or cost-effective manner compared
to some other methods.
[0006] A method of making a knitted shoe component described
herein, in some embodiments, is carried out using a knitting
machine, such as a V-bed knitting machine, having a front needle
bed and a back needle bed. A four-bed flat knitting machine may
also be used to carry out a method described herein. Such a method
can comprise knitting one or more fibers to form a toe portion;
knitting one or more fibers to form a first wing portion; and
knitting one or more fibers to form a second wing portion. The
first wing portion has a first edge comprising a plurality of
stitches, and the second wing portion has a second edge comprising
a plurality of stitches. Moreover, the first and second wing
portions each extend from the toe portion and are knittingly
connected to the toe portion. In addition, the first and second
wing portions are laterally separated from one another by an
initial separation distance. The separation distance can be
relative to the stitches of the first and second edges. A knitting
method described herein, in some cases, further comprises reducing
the lateral separation between the first wing portion and the
second wing portion from the initial separation distance to a
knitting separation distance such that the wing portions can be
connected or knitted together to form a seamless heel portion of
the shoe component.
[0007] As noted above, in some embodiments of a method described
herein, knitting is carried out using a V-bed knitting machine. In
some such methods, knitting the first wing portion to the second
wing portion comprises transferring stitches of the first edge
and/or second edge of the wing portions from a rib stitch or knit
configuration on the needle beds of the knitting machine to a
configuration in which the stitches are positioned on only the
front needle bed and/or only the back needle bed of the knitting
machine. Moreover, the method can further comprise optionally
knitting at least one additional knitted course on each of the
first and second wing portions to provide one stitch on each active
needle of the front needle bed and the back needle bed, followed by
racking the back needle bed and/or the front needle bed to reduce
the lateral separation between the first wing portion and the
second wing portion. In particular, the lateral separation can be
reduced from the initial separation distance to an intermediate
separation distance. In addition, this process can be repeated to
further reduce the separation distance between the wing portions.
In some cases, for example, the method further comprises
transferring the stitches of the first edge from the front needle
bed to the back needle bed and transferring the stitches of the
second edge from the back needle bed to the front needle bed (or
vice versa) and racking the back needle bed and/or the front needle
bed back to a previous racking position. In this manner, the
lateral separation between the first wing portion and the second
wing portion can be reduced from the intermediate separation
distance to a knitting separation distance.
[0008] Once the first and second wing portions are separated by a
knitting distance described herein, further knitting steps can be
carried out to complete the shoe component. In some embodiments,
one or more additional knitting steps are repeated until all or
substantially all of the active stitches of the first edge and all
or substantially all of the active stitches of the second edge have
been used to knittingly join the first wing portion and the second
wing portion to form the heel portion.
[0009] For example, in some cases, a method described herein
further comprises transferring the stitches of the first edge from
the back needle bed to the front needle bed and transferring the
stitches of the second edge from the front needle bed to the back
needle bed, followed by knitting at least one additional course on
each of the first edge and the second edge to reduce the number of
held stitches on each of the first edge and the second edge by at
least one stitch. It is to be understood that knitting at least one
additional course on each of the first edge and the second edge can
be equivalent to knitting at least one additional course on the
heel portion that is being formed by the joining of the first and
second wing portions. Moreover, a method described herein can
further comprise transferring the remaining held stitches of the
first edge from the front needle bed to the back needle bed and
transferring the remaining held stitches of the second edge from
the back needle bed to the front needle bed. In addition, if
desired, the method can further comprise carrying out additional
rounds of knitting, racking, and transferring of stitches. For
instance, in some embodiments, the method further comprises
knitting at least one additional course on each of the first edge
and the second edge (or on the heel portion) to further reduce the
number of held stitches on each of the first edge and the second
edge by at least one stitch; racking the back needle bed and/or the
front needle bed to reduce the lateral separation between the first
wing portion and the second wing portion; transferring the stitches
of the first edge from the back needle bed to the front needle bed
and transferring the stitches of the second edge from the front
needle bed to the back needle bed; knitting at least one additional
course on each of the first edge and the second edge (or on the
heel portion) to reduce the number of held stitches on each of the
first edge and the second edge by at least one stitch; racking the
back needle bed and/or the front needle bed to reduce the lateral
separation between the first wing portion and the second wing
portion; and transferring the stitches of the first edge from the
front needle bed to the back needle bed and transferring the
stitches of the second edge from the back needle bed to the front
needle bed. As noted above, the foregoing steps can be repeated as
needed or desired to complete the shoe component.
[0010] It is also possible to carry out a method described herein
using a four-bed flat knitting machine. Such a knitting machine, in
some cases, can have a front V needle bed, a back V needle bed, a
front top needle bed, and a back top needle bed. In some such
embodiments, knitting the first wing portion to the second wing
portion is carried out in a manner analogous to that described
above for a V-bed knitting machine, but adapted for a four-bed
knitting machine. For example, in some cases, knitting the first
wing portion to the second wing portion comprises transferring the
stitches of the first edge from a rib stitch configuration on the
back V needle bed to the front top needle bed and transferring the
stitches of the second edge from a rib stitch configuration on the
front V needle bed to the back top needle bed. The method further
comprises racking the back needle beds and/or the front needle beds
to reduce the lateral separation between the first wing portion and
the second wing portion from the initial separation distance to an
intermediate separation distance, followed by transferring the
stitches of the first edge from the front needle beds to the back
needle beds and transferring the stitches of the second edge from
the back needle beds to the front needle beds, and further followed
by racking the back needle beds and/or the front needle beds back
to the previous racking position to reduce the lateral separation
between the first wing portion and the second wing portion to a
knitting separation distance. Similarly, as with a method using a
V-bed knitting machine, a method of knitting together wing portions
with a four-bed flat knitting machine can further comprise
transferring the stitches of the first edge from the back needle
beds to the front needle beds and transferring the stitches of the
second edge from the front needle beds to the back needle beds;
knitting at least one additional course on each of the first edge
and the second edge to reduce the number of held stitches on each
of the first edge and the second edge by at least one stitch;
racking the back needle beds and/or the front needle beds to reduce
the lateral separation between the first wing portion and the
second wing portion; transferring the remaining held stitches of
the first edge from the front needle beds to the back needle beds
and transferring the remaining held stitches of the second edge
from the back needle beds to the front needle beds; racking the
back needle beds and/or the front needle beds back to the previous
racking position; knitting at least one additional course on each
of the first edge and the second edge to reduce the number of held
stitches on each of the first edge and the second edge by at least
one stitch; transferring the remaining held stitches of the first
edge from the back needle beds to the front needle beds and
transferring the remaining held stitches of the second edge from
the front needle beds to the back needle beds; and knitting at
least one additional course on each of the first edge and the
second edge to reduce the number of held stitches on each of the
first edge and the second edge by at least one stitch. Moreover,
the final racking, transferring, racking, knitting, transferring,
and knitting steps can be repeated until substantially all of the
stitches of the first edge and substantially all of the stitches of
the second edge have been used to knittingly join the first wing
portion to the second wing portion to form the heel portion.
[0011] Additionally, in some instances, a method described herein
further comprises knitting one or more fibers to form an insole
portion extending from the heel portion, wherein the insole portion
is knittingly connected to the heel portion. Moreover, in some
cases, the method also comprises joining the insole portion to one
or more of the first wing portion, the second wing portion, and the
toe portion. In some embodiments, joining is carried out by sewing
or linking.
[0012] In another aspect, knitted shoe components are described
herein which, in some embodiments, may exhibit one or more
desirable properties or features compared to other shoe components.
For example, in some cases, a knitted shoe component described
herein forms a three-dimensional shoe upper that is free of seams
in contact with the side, top, or heel of the foot of a wearer of
the shoe upper. A knitted shoe component described herein, in some
embodiments, comprises a toe portion; a first wing portion
extending from the toe portion and knittingly joined to the toe
portion; a second wing portion extending from the toe portion and
knittingly joined to the toe portion; and a heel portion, wherein
the first wing portion and the second wing portion are knittingly
joined to one another at the heel portion, including in a manner
that forms or defines the heel portion. In some cases, a knitted
shoe component described herein further comprises an insole portion
extending from the heel portion and knittingly joined to the heel
portion.
[0013] In still another aspect, methods of making a shoe are
described herein. In some embodiments, a method of making a shoe
comprises making a knitted shoe component in a manner described
hereinabove and attaching the knitted shoe component to one or more
additional shoe components, such as a tongue component and/or a
sole component.
[0014] In yet another aspect, shoes are described herein. In some
embodiments, a shoe described herein comprises a knitted shoe
component described hereinabove and one or more additional shoe
components attached to the knitted shoe component. The one or more
additional shoe components can include a tongue component, a sole
component, and/or another type of shoe component.
[0015] These and other embodiments are described in more detail in
the detailed description which follows.
BRIEF DESCRIPTION OF THE FIGURES
[0016] FIGS. 1A-1E illustrate components of a V-bed knitting
machine used to carry out a method of making a knitted shoe
component according to some embodiments described herein.
[0017] FIGS. 2A-2G illustrate schematically steps of a method of
making a knitting shoe component using a V-bed knitting machine
according to some embodiments described herein.
[0018] FIGS. 3A-3K illustrate schematically steps of a method of
making a knitted shoe component using a V-bed knitting machine
according to some embodiments described herein.
[0019] FIG. 4 illustrates a perspective view of a knitted shoe
component according to one embodiment described herein.
[0020] FIG. 5 illustrates a top-down schematic view of a knitted
shoe component according to one embodiment described herein.
[0021] FIG. 6 illustrates a perspective view of a four-bed flat
knitting machine used to carry out a method of making a knitted
shoe component according to some embodiments described herein.
[0022] FIGS. 7A-7G illustrate schematically steps of a method of
making a knitted shoe component using a four-bed knitting machine
according to some embodiments described herein.
[0023] FIGS. 8A-8J illustrate schematically steps of a method of
making a knitted shoe component using a four-bed knitting machine
according to some embodiments described herein.
[0024] FIG. 9 illustrates a perspective view of a knitted fabric
used to form a knitted shoe component according to one embodiment
described herein.
[0025] FIGS. 10-13 each illustrates a perspective view of a knitted
shoe component according to one embodiment described herein.
[0026] FIGS. 14-19 illustrate knitted shoe components and portions
of knitted shoe components according to some embodiments described
herein. FIGS. 14A, 15A, 16A, 17A, 18A, and 19A each illustrate a
side view of the back of a knitted shoe component. FIGS. 14B, 15B,
16B, 17B, 18B, and 19B illustrate side views of the knitted shoe
components of FIGS. 14A, 15A, 16A, 17A, 18A, and 19A,
respectively.
[0027] FIG. 20 illustrates a side view of a knitted shoe component
according to one embodiment described herein.
DETAILED DESCRIPTION
[0028] Embodiments described herein can be understood more readily
by reference to the following detailed description, examples, and
figures. Elements, apparatus, and methods described herein,
however, are not limited to the specific embodiments presented in
the detailed description, examples, and figures. It should be
recognized that these embodiments are merely illustrative of the
principles of the present invention. Numerous modifications and
adaptations will be readily apparent to those of skill in the art
without departing from the spirit and scope of the invention.
[0029] In addition, all ranges disclosed herein are to be
understood to encompass any and all subranges subsumed therein. For
example, a stated range of "1.0 to 10.0" should be considered to
include any and all subranges beginning with a minimum value of 1.0
or more and ending with a maximum value of 10.0 or less, e.g., 1.0
to 5.3, or 4.7 to 10.0, or 3.6 to 7.9.
[0030] All ranges disclosed herein are also to be considered to
include the end points of the range, unless expressly stated
otherwise. For example, a range of "between 5 and 10" should
generally be considered to include the end points 5 and 10.
I. Methods of Making a Knitted Shoe Component
[0031] In one aspect, methods of making a three-dimensional knitted
shoe component are described herein. As described hereinabove, such
a method can be carried out with a knitting machine. Any knitting
machine not inconsistent with the objectives of the present
invention may be used. In some cases, for example, a V-bed flat
knitting machine is used. In other cases, a four-bed flat knitting
machine is used. Further, a knitting machine described herein can
be used to carry out weft knitting. However, it should be noted
that a method of making a knitted shoe component described herein,
including a seamless three-dimensional knitted shoe component, can
be carried out without the use of a circular knitting machine or a
circular knitting method.
[0032] In addition, a knitting machine used in a method described
herein can be automated. For example, in some cases, a knitting
machine is configured to carry out a knitting process according to
needle-by-needle or stitch-by-stitch instructions provided by a
computer as a function of space and/or time. The computer can
include a processor and a memory storing computer-readable program
code portions that, in response to execution by the processor,
cause instructions to be provided to one or more components of a
knitting machine in a desired sequence.
[0033] In some embodiments, the knitting machine has a front needle
bed and a back needle bed, and the method comprises (a) knitting
one or more fibers to form a toe portion; (b) knitting one or more
fibers to form a first wing portion extending from the toe portion
and knittingly connected to the toe portion, the first wing portion
having a first edge comprising a plurality of stitches; and (c)
knitting one or more fibers to form a second wing portion extending
from the toe portion and knittingly connected to the toe portion
and laterally separated from the first wing portion by an initial
separation distance, the second wing portion having a second edge
comprising a plurality of stitches. A "fiber," for reference
purposes herein, can mean a fiber, yarn, or filament. A "lateral"
separation, for reference purposes herein, comprises a separation
in a plane or direction parallel to the long axis of the front and
back needle beds. The lateral separation direction can thus be
aligned with the knitting direction of the machine and
perpendicular to the direction of stitch formation of the front and
back needle beds. In addition, a "toe portion" of a knitted shoe
component, for reference purposes herein, can include the toe box
and the vamp of a shoe upper. A "vamp," for reference purposes
herein, can refer to the portion of a shoe upper that at least
partially covers the top part of the foot of a wearer between the
toes and the ankle. A shoe "upper," for reference purposes herein,
can comprise any portion of a shoe higher than the sole. Similarly,
a "wing portion," for reference purposes herein, can include all or
a portion of the medial or lateral portion of a shoe upper.
[0034] Returning to the knitting process, a method described herein
further comprises (d) disposing the stitches of the first edge and
the stitches of the second edge in a rib knit configuration on the
front needle bed and the back needle bed; and (e) knitting (or
knittingly connecting) the first wing portion to the second wing
portion to form a heel portion.
[0035] In some cases, knitting the first wing portion to the second
wing portion comprises (e1) transferring the stitches of the first
edge to the front needle bed and transferring the stitches of the
second edge to the back needle bed; and (e2) optionally knitting at
least one additional knitted course on each of the first and second
wing portions to provide one stitch on each active needle of the
front needle bed and the back needle bed. An "active" needle, for
reference purposes herein, comprises a needle that is holding at
least one stitch, as opposed to an "inactive" needle that is not
holding a stitch. In addition, in some cases, the method further
comprises (e3) racking the back needle bed and/or the front needle
bed to reduce the lateral separation between the first wing portion
and the second wing portion from the initial separation distance to
an intermediate separation distance; (e4) transferring the stitches
of the first edge from the front needle bed to the back needle bed
and transferring the stitches of the second edge from the back
needle bed to the front needle bed; and (e5) racking the back
needle bed and/or the front needle bed back to the position of step
(e1) to reduce the lateral separation between the first wing
portion and the second wing portion from the intermediate
separation distance to a knitting separation distance. It should be
noted that, in some embodiments, the position of step (e1) can be
the "zero" position of the relevant needle beds and/or knitting
machine.
[0036] Further, as understood by one of ordinary skill in the art,
"racking" a needle bed of a knitting machine described herein
comprises moving the needle bed laterally relative to another
needle bed, such as a needle bed in facing opposition to the
"racked" needle bed. A "knitting separation distance," for
reference purposes herein, comprises a distance between two edges
of stitches that is sufficiently small for the two edges to be
knittingly joined to one another by the knitting machine using a
rib knit configuration of the stitches on a front needle bed and a
back needle bed (although it is be understood that knitting may
subsequently include configurations other than a rib knit
configuration). In some cases, therefore, a knitting separation
distance is equal to or greater than a maximum racking distance of
the rib knit configuration. The "maximum racking distance" of the
rib knit configuration, for reference purposes herein, comprises
the maximum distance that the front needle bed(s) and/or the back
needle bed(s) can be racked without breaking one or more loops of
the rib knit configuration or one or more needles of a front needle
bed and/or a back needle bed. Further, the maximum racking distance
of a rib knit configuration can vary based on one or more of the
needle gauge, the needle type, the needle material, the fiber
material, the fiber denier, and the configuration of the knitting
machine. In addition, a knitting separation distance described
herein can be a constant and uniform knitting separation distance
or a distance that varies as the knitting method progresses. In
particular, the knitting separation distance can decrease as the
two wings are brought together and joined according to a method
described herein. It is also possible for the knitting separation
distance to increase to some extent during the knitting process,
such as may be required to shape the heel portion or a heel pouch
defined by the heel portion.
[0037] Once the first and second wing portions are separated by a
knitting distance described herein, further knitting steps can be
carried out to complete the shoe component. In particular, further
knitting steps can be carried out to actually form the heel portion
itself or to "close the heel" of the shoe component. In some cases,
an initial step in the actual heel closing or heel forming process
(once an appropriate knitting distance has been obtained and once
the stitches and needle beds have been placed in an appropriate
position described herein) comprises forming or knitting a welt. A
"welt," as understood by one of ordinary skill in the art, can
refer to a finished edge of an edge knit first knitted fabric,
component, or workpiece. Such a welt, in some instances, can
prevent the fabric, component, or fabric from rolling up or
otherwise losing its intended geometry. A welt formed in a method
described herein can be any type of welt not inconsistent with the
objectives of the present invention. In some embodiments, for
example, the welt is a "French" or "tubular" welt. A welt can also
be an "English" or "rolled" welt or a "racked" welt. Additionally,
as described further hereinbelow, a welt formed in a method
described herein can have any desired thickness. Moreover, it is to
be understood that a welt described herein can be a separate
portion of material to which the first and second wing portions are
each subsequently joined, including by a knitting process.
[0038] Thus, in some cases, knitting the first wing portion to the
second wing portion to form the heel portion further comprises (e6)
transferring the stitches of the first edge from the back needle
bed to the front needle bed and transferring the stitches of the
second edge from the front needle bed to the back needle bed; and
(e7) knitting or forming a welt between the first wing portion and
the second wing portion. In some embodiments, the welt at least
partially spans the needles disposed in the lateral separation
distance between the first wing portion and the second wing
portion. In some cases, the welt completely or substantially
completely spans this distance, such that at least about 90%, at
least about 95%, or at least about 98% of the lateral separation
distance is spanned by the welt. Further, in some instances,
knitting or forming a welt can be carried out in a plurality of
knitting steps. For example, in some embodiments, knitting the welt
comprises (e7-1) disposing a plurality of stitches in a rib knit
configuration on needles of the front needle bed and the back
needle bed within the "gap" defining the knitting separation
distance of the method. Moreover, in some cases, such a step can be
carried out by knitting at least one additional course on each of
the first and second wing portions to provide one stitch on each
active needle of the front needle bed and the back needle bed.
Additionally, to form a French or tubular welt, for instance,
knitting the welt can further comprise (e7-2) disposing or knitting
a plurality of stitches in a jersey knit configuration on needles
of the front needle bed and/or the back needle bed within the gap
defining the knitting separation distance of the method; and (e7-3)
disposing or knitting a plurality of stitches in a jersey knit
configuration on needles of the opposite needle bed (front or back)
as in step (e7-2), the needles being within the gap defining the
knitting separation distance. To faun another type of welt, such as
an English welt or a racked welt, steps (e7-2) and (e7-3) can be
replaced by knitting steps corresponding to these welt types, as
understood by one of ordinary skill in the art. Moreover, steps
(e7-2) and (e7-3) (or the corresponding steps for other welt types)
can be repeated any desired number of times to increase the
thickness of the welt.
[0039] Following formation of a welt in a manner described herein,
additional knitting steps can be undertaken to complete the heel
closure and the shoe component. In general, the additional knitting
steps can comprise knitting a plurality of additional courses on
each of the first edge and the second edge to reduce the number of
held stitches on each of the first edge and the second edge. A
"held" stitch, for reference purposes herein, comprises a stitch of
the first edge or the second edge held by a needle that is farther
from the second edge or first edge, respectively, than the knitting
separation distance. Knitting each additional course in a manner
described above can reduce the number of held stitches by one
stitch. Moreover, the number of additional courses knitted on the
first edge and the second edge can generally correspond to the
number of held stitches. In this manner, all of the held stitches
are eventually used to form the heel portion of the shoe component.
It is further to be understood that "closing the heel" of the shoe
component in such a manner can also include carrying out other
specific steps necessary to permit the knitting of the additional
courses using the held stitches of the first and second edges. Some
such steps are described further hereinbelow.
[0040] For example, in some embodiments, a method described herein
can further comprise (e8) knitting at least one additional course
on each of the first edge and the second edge to reduce the number
of held stitches on each of the first edge and the second edge by
at least one stitch; and (e9) racking the back needle bed and/or
the front needle bed to reduce the lateral separation between the
first wing portion and the second wing portion. Moreover, in some
cases, the method can further comprise (e10) transferring the
remaining held stitches of the first edge from the front needle bed
to the back needle bed and transferring the remaining held stitches
of the second edge from the back needle bed to the front needle
bed; and (e11) racking the back needle bed and/or the front needle
bed back to the position of step (e8). As described above, the
position of (e8), in some instances, comprises the zero position of
the needle beds and/or knitting machine. Following this racking
step, the method can further comprise (e12) knitting at least one
additional course on each of the first edge and the second edge to
reduce the number of held stitches on each of the first edge and
the second edge by at least one stitch in the same manner as
described hereinabove. Next, the method can comprise (e13) racking
the back needle bed and/or the front needle bed to reduce the
lateral separation between the first wing portion and the second
wing portion, where the racking of step (e13) is carried out in a
direction opposite to that carried out in step (e9) above. The
method can further comprise (e14) transferring the stitches of the
first edge from the back needle bed to the front needle bed and
transferring the stitches of the second edge from the front needle
bed to the back needle bed; and (e15) racking the back needle bed
and/or the front needle bed back to the position of step (e8).
[0041] Moreover, in some cases, knitting the first wing portion to
the second wing portion to form the heel portion or "close the
heel" further comprises repeating steps (e8) through (e15) above
until substantially all of the stitches of the first edge and
substantially all of the stitches of the second edge have been used
to knittingly join the first wing portion to the second wing
portion to form the heel portion. Thus, in this manner, a V-bed
knitting machine can be used to provide a knitted shoe upper that
is entirely or substantially entirely formed into a
three-dimensional shape using a knitting process only, as opposed
to a knitting process in combination with another joining process,
such as a sewing or linking process.
[0042] As described herein, it is also possible to make a knitted
shoe component such as a shoe upper using a knitting machine other
than a V-bed knitting machine. For example, in some cases, a
knitting machine having a front V needle bed, a back V needle bed,
a front top needle bed, and a back top needle bed is used. In such
cases, a method of making a knitted shoe component can comprise (a)
knitting one or more fibers to form a toe portion; (b) knitting one
or more fibers to form a first wing portion extending from the toe
portion and knittingly connected to the toe portion, the first wing
portion having a first edge comprising a plurality of stitches; (c)
knitting one or more fibers to form a second wing portion extending
from the toe portion and knittingly connected to the toe portion
and laterally separated from the first wing portion by an initial
separation distance, the second wing portion having a second edge
comprising a plurality of stitches; (d) disposing the stitches of
the first edge and the stitches of the second edge in a rib knit
configuration on the front V needle bed and the back V needle bed;
and (e) knitting the first wing portion to the second wing portion
to form a heel portion. Moreover, knitting the first wing portion
to the second wing portion to form the heel portion or "close the
heel" can be carried out by (e1) transferring stitches of the first
edge from the back V needle bed to the front top needle bed and
transferring stitches of the second edge from the front V needle
bed to the back top needle bed; (e2) racking the back needle beds
and/or the front needle beds to reduce the lateral separation
between the first wing portion and the second wing portion from the
initial separation distance to an intermediate separation distance;
(e3) transferring the stitches of the first edge from the front top
needle bed to the back V needle bed and from the front V needle bed
to the back top needle bed, and transferring the stitches of the
second edge from the back top needle bed to the front V needle bed
and from the back V needle bed to the front top needle bed; and
(e4) racking the back needle beds and/or the front needle beds back
to the position of step (e1) to reduce the lateral separation
between the first wing portion and the second wing portion from the
intermediate separation distance to a knitting separation
distance.
[0043] In addition, as with a method carried out using a V-bed
knitting machine, once a knitting separation distance between the
wing portions is obtained, it is possible to carry out additional
knitting steps with a four-bed knitting machine to form a seamless
knitted shoe component. In particular, further knitting steps can
be carried out to actually form the heel portion itself or to
"close the heel" of the shoe component. In some cases, an initial
step in the actual heel closing or heel forming process (once an
appropriate knitting distance has been obtained and once the
stitches and needle beds have been placed in an appropriate
position described herein) comprises forming or knitting a welt.
The welt can comprise any welt described hereinabove for a V-bed
knitting machine, such as a French welt, an English welt, or a
racked welt.
[0044] Therefore, in some cases, knitting the first wing portion to
the second wing portion further comprises (e5) transferring the
stitches of the first edge from the back top needle bed to the
front V needle bed and transferring the stitches of the second edge
from the front top needle bed to the back V needle bed; and (e6)
knitting or forming a welt between the first wing portion and the
second wing portion. In some embodiments, the welt at least
partially spans the needles disposed in the lateral separation
distance between the first wing portion and the second wing
portion. In some cases, the welt completely or substantially
completely spans this distance, such that at least about 90%, at
least about 95%, or at least about 98% of the lateral separation
distance is spanned by the welt. Further, in some instances,
knitting or forming a welt can be carried out in a plurality of
knitting steps. For example, in some embodiments, knitting the welt
comprises (e6-1) disposing a plurality of stitches in a rib knit
configuration on needles of the front needle beds and the back
needle beds within the "gap" defining the knitting separation
distance of the method. Further, in some cases, such a step can be
carried out by knitting at least one additional course on each of
the first and second wing portions to provide one stitch on each
active needle of the front needle beds and the back needle beds.
Additionally, to faun a French welt, for instance, knitting the
welt can further comprise (e6-2) disposing or knitting a plurality
of stitches in a jersey knit configuration on needles of the front
needle bed(s) or back needle bed(s) within the gap defining the
knitting separation distance; and (e6-3) disposing or knitting a
plurality of stitches in a jersey knit configuration on needles of
the opposite needle bed(s) (front or back) as in step (e6-2), the
needles being within the gap defining the knitting separation
distance. To form another type of welt, such as an English welt or
a racked welt, steps (e6-2) and (e6-3) can be replaced by knitting
steps corresponding to these welt types, as understood by one of
ordinary skill in the art. Moreover, steps (e6-2) and (e6-3) (or
the corresponding steps for other welt types) can be repeated any
desired number of times to increase the thickness of the welt.
[0045] Following formation of a welt in a manner described herein,
additional knitting steps can be undertaken to complete the heel
closure and the shoe component, as described above for a V-bed
knitting machine. In general, the additional knitting steps can
comprise knitting a plurality of additional courses on each of the
first edge and the second edge to reduce the number of held
stitches on each of the first edge and the second edge. Knitting
each additional course in a manner described above can reduce the
number of held stitches by one stitch. Moreover, the number of
additional courses knitted on the first edge and the second edge
can generally correspond to the number of held stitches. In this
manner, all of the held stitches can eventually be used to foul'
the heel portion of the shoe component. Again, as with a V-bed
knitting machine, it is further to be understood that "closing the
heel" of the shoe component can also include carrying out other
specific steps necessary to permit the knitting of the additional
courses using the held stitches of the first and second edges. Some
such steps are described further hereinbelow.
[0046] For example, in some embodiments, a method described herein
can further comprise (e7) knitting at least one additional course
on each of the first edge and the second edge to reduce the number
of held stitches on each of the first edge and the second edge by
at least one stitch; (e8) transferring the remaining held stitches
of the first edge from the back V needle bed to the front top
needle bed and transferring the remaining held stitches of the
second edge from the front V needle bed to the back top needle bed;
(e9) racking the back needle beds and/or the front needle beds to
reduce the lateral separation between the first wing portion and
the second wing portion; (e10) transferring the remaining held
stitches of the first edge from the front top needle bed to the
back V needle bed and from the front V needle bed to the back top
needle bed, and transferring the remaining held stitches of the
second edge from the back top needle bed to the front V needle bed
and from the back V needle bed to the front top needle bed; and
(e11) racking the back needle beds and/or the front needle beds
back to the position of step (e7). The position of step (e7), in
some instances, comprises a zero position of the needle beds and/or
the knitting machine. The method can further comprise (e12)
transferring the remaining held stitches of the first edge from the
back top needle bed to the front V needle bed and transferring the
remaining held stitches of the second edge from the front top
needle bed to the back V needle bed.
[0047] Moreover, in some embodiments, knitting the first wing
portion to the second wing portion further comprises repeating
steps (e7) through (e12) above until substantially all of the
stitches of the first edge and substantially all of the stitches of
the second edge have been used to knittingly join the first wing
portion to the second wing portion to form or close the heel
portion.
[0048] Additionally, as an alternative to carrying out steps
(e7)-(e12) above, it is also possible to close the heel using a
four-bed knitting machine by maintaining a rib knit configuration
on both the first wing portion and the second wing portion. In such
an instance, the method can further comprise knitting a plurality
of additional courses on each of the first edge and the second edge
until all of the held stitches on each of the first edge and the
second edge are knittingly joined in a rib knit configuration to
complete formation of the heel portion.
[0049] Regardless of the type of knitting machine used, methods
described herein can include reducing the distance between wing
portions of a knitted shoe component. For example, the distance
between wing portions can be reduced from an initial separation
distance to an intermediate separation distance and/or a knitting
separation distance. The initial separation distance can be any
distance not inconsistent with the objectives of the present
invention. Moreover, the initial separation distance can depend on
a desired size or shape of the knitted shoe component and/or the
configuration of the knitting machine. In some cases, the initial
separation distance is greater than a maximum racking distance of
the stitches of the first edge and the stitches of the second edge
in a rib knit configuration described herein. In some embodiments,
the initial separation distance is greater than about 3 inches. In
other cases, the initial separation distance is greater than about
4 inches or greater than about 5 inches. In some instances, the
initial separation distance is between about 1.5 inches and about
24 inches, between about 2 inches and about 18 inches, between
about 2 inches and about 12 inches, between about 3 inches and
about 24 inches, between about 3 inches and about 10 inches,
between about 4 inches and about 12 inches, or between about 4
inches and about 10 inches. Other initial separation distances may
also be used in a method described herein.
[0050] Similarly, in some embodiments, the knitting separation
distance of the method is equal to or less than the maximum racking
distance. In some instances, the knitting separation distance is
about 1 inch. In some cases, the knitting separation distance is
between about 0.5 inches and about 1.5 inches or between about 1
inch and about 2 inches. In some embodiments, the knitting
separation distance is greater than about 1 inch, greater than
about 1.5 inches, or greater than about 2 inches. In some cases,
the knitting separation distance can be less than about 1 inch or
less than about 0.5 inches. In some embodiments, for instance, the
knitting separation distance corresponds to the width of two
needles of the front needle bed(s) and two needles of the back
needle bed(s).
[0051] Additionally, the first and/or second wing portions joined
according to a method described herein can have any size and/or
shape not inconsistent with the objectives of the present
invention. In some cases, the size and/or shape of the first and/or
second wing portion is selected based on a desired configuration of
the resulting heel portion. For example, in some instances, the
first and/or second wing portions are selected to provide a shaped
heel portion. In addition, the first and/or second wing portion can
include one or more features or subcomponents. In some cases, for
instance, forming the first wing portion and/or the second wing
according to a method described herein includes forming eyelets in
the first wing portion and/or the second wing portion. The eyelets
can be seamless and integrally and/or simultaneously constructed
with the first wing portion and/or second wing portion. Further,
such eyelets, if desired, can be used to receive shoe laces,
hook-and-loop attachment strips such as Velcro strips, or other
attachment or fastening components of a shoe or shoe component.
[0052] Moreover, in some embodiments, a method of making a knitted
shoe component described herein further comprises one or more
additional steps following formation of a heel portion, including
one or more additional knitting steps. For example, in some cases,
a method described herein further comprises (g) knitting one or
more fibers to form an insole portion extending from the heel
portion, wherein the insole portion is knittingly connected to the
heel portion. Additionally, in some such instances, a method
further comprises (h) joining the insole portion to one or more of
the first wing portion, the second wing portion, and the toe
portion at a location other than the knitted junction of the insole
portion with the heel portion. Any suitable method of further
joining the insole portion to one or more other components of the
knitted shoe component can be used. For example, in some cases, the
insole portion is joined to one or more of the first wing portion,
the second wing portion, and the toe portion by sewing or linking.
An "insole" portion, for reference purposes herein, can define the
interior bottom of a shoe or shoe component and can be positioned
directly beneath the foot of a wearer of the shoe or shoe
component.
[0053] Further, it is to be understood that methods of making a
knitted shoe component described herein can be carried out using
any fibers not inconsistent with the objectives of the present
invention, where "fibers" can refer collectively to fibers, yarns,
and filaments. In some cases, for instance, a knitted shoe
component is formed from a single component yarn, a bi- component
yarn, or a combination thereof. A bi-component yarn can have a
sheath/core structure, a side-by-side structure, or an
islands-in-the-sea structure. Other bi-component yarn structures
can also be used. Further, in some embodiments, a knitted shoe
component is formed from a monofilament yarn, a multifilament yarn,
or a combination thereof. A yarn used in a method described herein
may also include separate filaments formed from different
materials, or a plurality of filaments that are each formed from
two or more different materials.
[0054] Additionally, in some instances, a knitted shoe component
described herein is at least partially formed from an elastomeric
yarn or a heat-fusible yarn. For example, in some embodiments,
stable and elastic single component multifilament and/or
monofilament yarns are used. In some such cases, the yarns can be
formed from low melting point polymers, such as polymers having a
melting point below about 200.degree. C., 150.degree. C., below
about 100.degree. C., or below about 80.degree. C. In some
embodiments, the yarns can be formed from polymers having a melting
point between about 80.degree. C. and about 150.degree. C. Such
yarns can be heated, with or without pressure, to cause the low
melting components to melt and flow, thereby modifying the physical
properties of the knitted shoe component, including by serving as
an adhesive. In other cases, stable and elastic bi-component
multifilament and/or monofilament yarns are used. In some such
embodiments, the yarns can be formed from low melting polymers in
combination with higher melting point polymers (such as polyester
or nylon), such that the low melting polymer components but not the
higher melting components of the yarns can be made to melt and flow
by the application of heat with or without pressure, thereby
modifying the physical properties of the knitted shoe component in
a desired manner, including by providing an adhesive element and/or
structural support.
[0055] A fiber, yarn, or filament or a portion of a fiber, yarn, or
filament described here can comprise or be formed from any material
not inconsistent with the objectives of the present invention. In
some embodiments, for example, a fiber, yarn, or filament comprises
or is formed from a synthetic material such as nylon or another
polyamide, polyester, polyethylene, polypropylene, polybutylene, or
another polyolefin, or polyacrylic. In other cases, a fiber, yarn,
or filament comprises or is formed from a natural fiber material
such as cotton, wool, or silk. Other fibers, yarns, and filament
materials may also be used, such as regenerated cellulose or rayon.
A fiber, yarn, or filament described herein can also be coated with
one or more additional materials to provide a desired property. In
some cases, for instance, a fiber, yarn, or filament can be coated
with a fluorocarbon such as polytetrafluoroethylene. A fiber, yarn,
or filament described herein can also include one or more
additives, including polymer additives, which can provide heat
absorption and/or heat reflectivity properties. Non-limiting
examples of thermally conductive additives which may be used in
some embodiments described herein include ceramics such as aluminum
nitride and/or boron nitride ceramics, metals such as aluminum or
copper, and nanoscale carbon materials such as carbon fibers,
carbon nanotubes, and graphite nanoplatelets. Additives comprising
thermochromic or photochromic pigment and dye materials may also be
used. Such pigment and dye materials can change color in response
to heat or light. It is also possible to incorporate one or more
antimicrobial or antifungal materials into or onto a fiber, yarn,
or filament described herein. Non-limiting examples of
antimicrobial or antifungal materials that may be used in some
embodiments described herein include inorganic, organic, and/or
metal-containing antimicrobial materials such as materials
comprising silver, copper, and/or zinc, and quaternary silane-based
antimicrobial materials.
[0056] Moreover, a fiber, yarn, or filament described herein can
have any size, shape, and/or denier not inconsistent with the
objectives of the present invention.
[0057] In addition, a knitted shoe component formed by a method
described herein can comprise regions having the same or differing
properties. For example, in some cases, a knitted shoe component
can have regions of the same or differing stability, rigidity,
elasticity, support, softness, cover, durability against fraying,
durability against unraveling, cushioning, compression,
breathability, weight, density, color, water wicking ability,
and/or water resistance. Further, the properties of a region of a
knitted shoe component described herein can be selected based on
the type of knitting process, the type of stitch, and/or the
chemical composition or type of fiber, yarn, or filament used to
form the region. Thus, by selectively forming regions having
differing properties, a shoe component can be provided that has
both a unitary knitted structure and also complex features, varied
regions, or features or regions selected for specific applications.
The unitary structure can be formed by a single knitting operation
according to a method described herein.
[0058] For example, a knitted shoe component made by a method
described herein can have one or more regions of high breathability
(such as may be provided by the use of a meshed stitch structure),
one or more regions of high elasticity (such as may be provided by
the use of an elastomeric yarn), one or more regions of high
rigidity (such as may be provided by the use of a non-elastomeric
yarn), and/or one or more regions that can be shaped using a heat
treatment (such as may be provided by the use of a fusible yarn).
In another instance, a knitted shoe component made by a method
described herein can include relatively soft regions and relatively
abrasion resistant regions. A soft region may be located in the
inside or interior of the knitted shoe component, and an abrasion
resistant region may be located on the outside or exterior of the
knitted shoe component, relative to the foot of a wearer.
Selectively varying the type of knitting process, the type of
stitch, and/or the chemical composition or type of fiber, yarn, or
filament used during a method described herein can also provide a
knitted shoe component having desired aesthetic, design, or texture
elements. For example, in some embodiments, a knitted shoe
component does not have a uniform or substantially uniform
thickness, but instead defines contours, ridges, or other
patterns.
II. Knitted Shoe Components
[0059] In another aspect, three-dimensional knitted shoe components
are described herein. A "three-dimensional" knitted shoe component,
for reference purposes herein, is a shaped component formed by
arranging one or more fabrics in a three-dimensional configuration,
as opposed to a "flat" configuration of the fabrics. Such knitted
shoe components can be formed by a method described hereinabove in
Section I. Further, the knitted shoe components can have any form
or define any structural or other feature of a shoe not
inconsistent with the objectives of the present invention. In some
embodiments, for instance, a knitted shoe component described
herein comprises, forms, or defines a shoe upper. In other cases, a
knitted shoe component comprises, forms, or defines an interior
lining of a shoe or other footwear, such as a sock liner.
[0060] Further, a knitted shoe component described herein can
exhibit a stitch and/or knit structure corresponding to steps of a
method described hereinabove in Section I. For example, in some
cases, a three-dimensional knitted shoe supper described herein has
a stitch and/or knit structure that is continuous, repeating,
and/or seamless throughout the entire upper or a portion or region
of the upper, such as a heel portion. A knitted shoe component
described herein can thus have a knit or stitch structure that
distinguishes the shoe component from other shoe components,
including some other shoe components made by a method that differs
from a method described herein or that is not capable of forming a
knit or stitch structure such as those described herein. For
example, in some embodiments, the stitch and/or knit structure of a
knitted shoe component described herein differs from the stitch
and/or knit structure provided by a circular knitting process.
[0061] In some embodiments, a knitted shoe component described
herein comprises a toe portion; a first wing portion extending from
the toe portion and knittingly joined to the toe portion; a second
wing portion extending from the toe portion and knittingly joined
to the toe portion; and a heel portion, wherein the first wing
portion and the second wing portion are knittingly joined to one
another at the heel portion. In addition, in some cases, a knitted
shoe component described herein further comprises an insole portion
extending from the heel portion and knittingly joined to the heel
portion. It is to be understood that the foregoing portions of a
knitted shoe component described herein can each exhibit a knit or
stitch structure corresponding to a method described hereinabove in
Section I. For example, in some embodiments, a knitted shoe
component described herein comprises a welt (such as a welt
described hereinabove in Section I) in the heel portion of the shoe
component, in addition to a welt that may be included in another
portion of the shoe component, such as the toe portion. Therefore,
in some instances, a knitted shoe component described herein
includes a plurality of welts, including a first welt in the toe
portion and a second welt in the heel portion of the knitted shoe
component.
[0062] Moreover, in some embodiments, a knitted shoe component
described herein does not include a seam. A "seam," for reference
purposes herein, comprises a line or ridge where two or more
portions or layers of fabric are connected by stitches, staples, an
adhesive, or a similar joining means. Thus, the term "seam" does
not include a line or area at which two portions of fabric (such as
a first and second wing portion described herein) are joined by a
continuous knitting process, such as a knitting process described
herein. The presence of one or more seams in a shoe component can
cause abrasion or other discomfort to a wearer, or else require
covering or cushioning in some manner. Therefore, a seamless
knitted shoe component described herein can provide manufacturing
and use advantage, compared to some other knitted shoe
components.
III. Methods of Making a Shoe
[0063] In another aspect, methods of making a shoe are described
herein. A "shoe," for reference purposes herein, can comprise any
outer footwear not inconsistent with the objectives of the present
invention. For example, in some cases, a shoe can be an athletic
shoe or other athletic footwear, including a shoe or other footwear
specifically designed for baseball, basketball, boating or other
water sports, cross-training, football, hiking, hockey, running,
soccer, or walking activities. A shoe can also be a non-athletic
shoe or other footwear, such as a deck shoe, dress boot, dress
shoe, loafer, sandal, or work boot.
[0064] A method of making a shoe described herein, in some
embodiments, comprises making a knitted shoe component according to
a method described hereinabove in Section I and attaching the
knitted shoe component to one or more additional shoe components.
Any additional shoe components not inconsistent with the objectives
of the present invention may be used. In addition, one or more
additional shoe components can be attached to a knitted shoe
component described herein in any manner known in the art and not
inconsistent with the objectives of the present invention. For
example, in some cases, an additional shoe component comprises a
tongue component. The tongue component can be sewn, stapled, glued,
or otherwise attached to the knitted shoe component, which may
comprise a shoe upper.
[0065] In other cases, an additional shoe component comprises a
sole component. A sole component can include a midsole and/or an
outsole. An "outsole," for reference purposes herein, comprises the
portion of the shoe in direct contact with the ground during normal
use of the shoe. Thus, the outsole can be the portion of the shoe
farthest from the upper, including an upper formed defined by a
knitted shoe component described herein. A "midsole," for reference
purposes herein, can comprise a layer disposed between the outsole
and an insole of the shoe. In some cases, the midsole of a shoe
described herein includes or is formed from a shock absorbent
material. Moreover, a sole component can be attached to a knitted
shoe component in any manner not inconsistent with the objectives
of the present invention. In some cases, for instance, a sole
component is glued to a knitted shoe component described herein.
Other methods of attachment may also be used.
IV. Shoes
[0066] In another aspect, shoes are described herein. A shoe
described herein can be an athletic shoe or other athletic
footwear, including a shoe or other footwear specifically designed
for baseball, basketball, boating or other water sports,
cross-training, football, hiking, hockey, running, soccer, or
walking activities. A shoe can also be a non-athletic shoe or other
footwear, such as a deck shoe, dress boot, dress shoe, loafer,
sandal, or work boot. Further, a shoe described herein can be
formed by a method described hereinabove in Section III. Further, a
shoe or component of a shoe can have any structure not inconsistent
with the objectives of the present invention, including any
structure described hereinabove in Section II or Section III.
[0067] In some embodiments, a shoe comprises a knitted shoe
component described hereinabove in Section II and one or more
additional shoe components attached to the knitted shoe component.
Any additional shoe components not inconsistent with the objectives
of the present invention may be used. In some cases, for instance,
an additional shoe component comprises a tongue component. In other
cases, an additional shoe component comprises a sole component,
such as a midsole or outsole.
[0068] Some embodiments described herein are further illustrated in
the following non- limiting examples. The following examples and
the foregoing description are directed to the fabrication of
various three-dimensional shoes and shoe components, including
seamless knitted shoes and shoe components. However, it should be
noted that methods described herein, including methods of reducing
the lateral separation distance between knitted fabric portions,
can be expanded and applied more generally to the knitting of other
three-dimensional fabrics that are not necessarily a shoe
component.
EXAMPLE 1
V-Bed Knitting
[0069] A method of making a knitted shoe component using a V-bed
knitting machine according to one embodiment described herein is
illustrated schematically in FIGS. 1-5. Specifically, FIG. 1
illustrates the general nomenclature used for V-bed knitting
machine diagrams. FIGS. 2 and 3 illustrate an exemplary method of
forming or "closing" the heel portion of a shoe upper formed using
a V-bed knitting machine. FIGS. 4 and 5 each illustrate a finished
knitted shoe component.
[0070] With reference to FIG. 1A and FIG. 1B, a front needle bed
(110) and a back needle bed (120) are each depicted schematically
as a series of short line segments (111, 121, respectively). The
line segments (111, 121) schematically represent individual needles
of the front needle bed (110) and the back needle bed (120). When
the needles (111, 121) of the front needle bed (110) and the back
needle bed (120), respectively, are facing one to one from first to
last, the racking of the beds (110, 120) is said to be in the
"zero" or "0" position, as illustrated in FIG. 1C. However, it is
to be understood that the needle beds (110, 120) in a zero position
can also be in a rib gaited arrangement. At various points during
operation of the knitting machine, the front needle bed (110)
and/or the back needle bed (120) can be "racked" a desired number
of needles, as described hereinabove and as illustrated in FIG. 1D.
As depicted in FIG. 1D, the back needle bed (120) has undergone a
10-needle racking to the left (as indicated by the arrow pointing
to the left in FIG. 1D). However, a needle bed (110, 120) can slide
or be racked in either direction (left or right) and may also be
racked a different number of needles, other than 10 needles. In
addition, racking is generally reversible. For example, as
illustrated in FIG. 1E, the front needle bed (110) and the back
needle bed (120) are again in a "0" position due to a racking in
the opposite direction of the racking in FIG. 1D.
[0071] As described herein, a knitted shoe component can be formed
from first and second wing portions (or "left" and "right" wings).
These wing portions can be initially disposed in a knitting machine
in a rib knit configuration. Moreover, the wing portions can be
considerably separated from one another in a lateral direction (by
an initial separation distance). To successfully join the wing
portions to form or close the heel using a knitting process, the
wing portions must be moved closer to one another (until a
"knitting" separation distance is obtained, which may be about 1
inch in some cases). In general, the distance between wing portions
disposed in a V-bed knitting machine as described herein can be
reduced by racking. However, it is not possible to carry out a
sufficiently large racking with both needle beds tied on a rib
knit. Therefore, a series of stitch transfer and racking steps
according to a method described herein must be carried out to
permit successful closing of the heel. These steps are illustrated
schematically in FIGS. 2 and 3. However, for purposes of clarity
and emphasis, it should be noted that not every feature is
necessarily shown or labeled in each of the various portions of
FIGS. 2 and 3.
[0072] With reference to FIG. 2A, a first wing portion or left wing
(210) and a second wing portion or right wing (220) are depicted
schematically on the front needle bed (110) and the back needle bed
(120) of a V-bed knitting machine. For illustration purposes, only
the edge of the first wing portion (210) and the edge of the second
wing portion (220) are illustrated schematically. Moreover,
throughout this example, the term "wing portion" and the associated
reference numeral (210 or 220) are used to refer to both a specific
wing portion and also the edge of the wing portion, and the context
of the reference will be used to provide further clarity. It is
also to be understood that the first (210) and second (220) wing
portions also include previously knitted materials not shown in
FIG. 2A. Additionally, the active stitches (211, 221) of the first
(210) and second (220) wing portions (or edges), respectively, are
depicted as loops on the needle beds (110, 120). As illustrated in
FIG. 2A, the active stitches (211, 221) of the first (210) and
second (220) wing portions are disposed in a rib knit
configuration, which is depicted as a double loop in FIG. 2A. In
addition, there is a gap or lateral separation distance (130)
between the first (210) and second (220) wing portions. At the
beginning of the heel closing process, the gap (130) can correspond
to an initial lateral separation distance described
hereinabove.
[0073] To reduce the gap or lateral separation distance (130), a
series of stitch transfer, racking, and (optionally) knitting steps
can be performed in a manner described herein. These steps (denoted
as (e1) through (e5)) are illustrated schematically in FIGS. 2B-2F.
With reference to FIG. 2B, the method of the present example
comprises (e1) transferring the stitches (211) of the first edge or
wing portion (210) to the front needle bed (110) and transferring
the stitches (221) of the second edge or wing portion (220) to the
back needle bed (120), as illustrated by the arrows in FIG. 2B. By
transferring the active stitches (211, 221) in this manner, the
back needle bed (120) is cleared on the left wing (210), and the
front needle bed (110) is cleared on the right wing (220). Next, in
FIG. 2C (and step (e2)), at least one additional course is
optionally knitted on each of the first (210) and second (220)
wings. Then, with reference to FIG. 2D, the method comprises (e3)
racking the back needle bed (120) to reduce the lateral separation
distance between the first wing portion (110) and the second wing
portion (120) from the initial separation distance (130 in FIGS.
2A-2C) to an intermediate separation distance (130 in FIGS. 2D and
2E). As illustrated by the arrow in FIG. 2D, the back needle bed
(120) is racked to the left. However, as described above, it is
also possible to rack the front needle bed (110) instead, such as
to the right in FIG. 2D.
[0074] Following the reduction of the gap (130) in FIG. 2D, a step
(e4) is carried out in FIG. 2E in which the active stitches (211)
of the first edge (210) are transferred from the front needle bed
(110) to the back needle bed (120), and the stitches (221) of the
second edge (220) are transferred from the back needle bed (120) to
the front needle bed (110). Next, with reference to FIG. 2F, a
racking step (e5) is carried out in which the back needle bed (120)
is racked back to the position of step (e1) to further reduce the
lateral separation distance (130) between the first wing portion
(210) and the second wing portion (220) from the intermediate
separation distance (130 in FIGS. 2D and 2E) to a knitting
separation distance (130 in FIGS. 2F and 2G). Again, it is to be
understood that although the back needle bed (120) is depicted in
FIG. 2 as the bed that is racked, it is also possible to rack the
front needle bed (110).
[0075] Moreover, once the gap (130) is reduced to a knitting
separation distance in a manner described hereinabove, the active
stitches (211, 221) of the first (210) and second (220) wing
portions can be placed in a position appropriate for beginning the
next stage of the method, the heel closure itself, as illustrated
in FIG. 2G. In particular, in FIG. 2G, a step (e6) is carried out.
Step (e6) comprises transferring the stitches (211) of the first
edge (210) from the back needle bed (120) to the front needle bed
(110) and transferring the stitches (221) of the second edge (220)
from the front needle bed (110) to the back needle bed (120).
[0076] Once the first (210) and second (220) wing portions are
separated by a knitting distance (130) and the stiches (211, 221)
are disposed on the correct needle beds (110, 120), further
knitting steps are carried out to complete the shoe component. In
the embodiment illustrated in FIG. 3, the first step in this
portion of the method is the step (e7) of knitting or forming a
welt (230) between the first wing portion (210) and the second wing
portion (220). Specifically, the welt (230) is formed by first
(e7-1) disposing a plurality of stitches in a rib knit
configuration on needles of the front needle bed (110) and the back
needle bed (120) within the gap defining the knitting separation
distance of the method, as illustrated in FIG. 3A. Next, to form a
French welt, the method illustrated in FIG. 3 comprises (e7-2)
disposing or knitting a plurality of stitches in a jersey knit
configuration on needles of the back needle bed within the gap
defining the knitting separation distance of the method (see FIG.
3B); and (e7-3) disposing or knitting a plurality of stitches in a
jersey knit configuration on needles of the opposite needle bed
(front) as in step (e7-2), the needles being within the gap
defining the knitting separation distance (see FIG. 3C) It should
be noted that, to form another type of welt, such as an English
welt or a racked welt, steps (e7-2) and (e7-3) can be replaced by
knitting steps corresponding to these welt types, as understood by
one of ordinary skill in the art. Moreover, steps (e7-2) and (e7-3)
(or the corresponding steps for other welt types) can be repeated
any desired number of times to increase the thickness of the
welt.
[0077] Following formation of the welt (230), the method of the
present example further comprises (e8) knitting at least one
additional course on each of the first edge (210) and the second
edge (220) to reduce the number of held stitches on each of the
first edge (210) and the second edge (220) by at least one stitch
(see FIG. 3D; held stitches not shown); and (e9) racking the back
needle bed (120) to reduce the lateral separation between the first
wing portion (210) and the second wing portion (220) (see FIG. 3E).
The method also comprises (e10) transferring the remaining held
stitches of the first edge (210) from the front needle bed (110) to
the back needle bed (120) and transferring the remaining held
stitches of the second edge (220) from the back needle bed (120) to
the front needle bed (110) (see FIG. 3F); and (ell) racking the
back needle bed (120) back to the position of step (e8) (see FIG.
3G). As illustrated in FIG. 3, the position of (e8) comprises the
zero position of the needle beds (110, 120). Following this racking
step, a step (e12) is carried out in which at least one additional
course is knitted on each of the first edge (210) and the second
edge (220) to reduce the number of held stitches on each of the
first edge (210) and the second edge (220) by at least one stitch
in the same manner as described hereinabove (see FIG. 3H). Next,
the back needle bed (120) is racked in step (e13) to reduce the
lateral separation between the first wing portion (210) and the
second wing portion (220), where the racking of step (e13) is
carried out in a direction opposite to that carried out in step
(e9) above (see FIG. 31). The method further comprises (e14)
transferring the stitches of the first edge (210) from the back
needle bed (120) to the front needle bed (110) and transferring the
stitches of the second edge (220) from the front needle bed (110)
to the back needle bed (120) (see FIG. 3J); and (e15) racking the
back needle bed (120) back to the position of step (e8) (see FIG.
3K).
[0078] To complete foil cation of the heel portion, steps (e8)
through (e15) are repeated until substantially all of the stitches
of the first edge (210) and substantially all of the stitches of
the second edge (220) have been used to knittingly join the first
wing portion (210) to the second wing portion (220) to form the
heel portion. Thus, in this manner, a V-bed knitting machine can be
used to provide a knitted shoe upper that is entirely or
substantially entirely formed into a three-dimensional shape using
a knitting process only, as opposed to a knitting process in
combination with another joining process, such as a sewing or
linking process.
[0079] The finished knitted shoe component (200) formed by the
method is illustrated in FIG. 4 and FIG. 5. FIG. 4 illustrates a
perspective view of the knitted shoe component (200) comprising a
first wing portion (210) and a second wing portion (220) knittingly
joined together to form a heel portion (250). FIG. 5 illustrates a
schematic top-down view of the fabric of the knitted shoe component
(200), with all contours in the dimension perpendicular to the page
of FIG. 5 flattened for illustration purposes. As shown in FIG. 5
and as described herein, the knitted shoe component (200) is formed
by first knitting the toe portion (240) and then the first (210)
and second (220) wing portions, followed by forming the heel
portion (250) in a manner described hereinabove.
EXAMPLE 2
Four-Bed Flat Knitting
[0080] A method of making a knitted shoe component using a four-bed
flat knitting machine according to one embodiment described herein
is illustrated schematically in FIGS. 6-8. Specifically, FIG. 6
illustrates a perspective view of a four-bed flat knitting machine
(100) that can be used to perform the method, and FIGS. 7 and 8
illustrate numbered steps of an exemplary method of forming or
"closing" the heel portion of a shoe upper formed using a four-bed
flat knitting machine such as the machine (100) of FIG. 6. The
knitting machine of FIG. 6 comprises a front V needle bed (110A), a
back V needle bed (120A), a front top needle bed (110B) and a back
top needle bed (120B). For convenience of reference, the front V
needle bed (110A) and the front top needle bed (110B) may be
referred to collectively as the "front needle beds (110)."
Similarly, the back V needle bed (120A) and the back top needle bed
(120B) may be referred to collectively as the "back needle beds
(120)." Further, as illustrated in FIG. 7 and FIG. 8, the front
needle beds (110) and the back needle beds (120) can each be
depicted schematically as "double" needle beds, in contrast to the
"single" needle beds depicted in the figures associated with
Example 1 above, where a "double" needle bed includes two needles
per lateral position. More particularly, as illustrated in FIGS. 7
and 8, a dashed box containing two needles is used to represent the
needle of each back bed (or each front bed) corresponding to the
same general lateral position. The "left" needles in each box and
the "right" needles in each box, respectively, refer to needles of
a different needle bed. For example, the right needle within a
given box depicted in the front needle beds (110) can refer to a
needle of the front top needle bed (110B) and the left needle
within a given box depicted in the front needle beds (110) can
refer to a needle of the front V needle bed (110A). Additionally,
when reference is made to transferring stitches from the front
needle beds to the back needle beds (or vice versa), it is to be
understood that the transfer can be from a specific front needle
bed (i.e., the front V needle bed or the front top needle bed) and
to a specific back needle bed (i.e., the back V needle bed or the
back top needle bed), as described, for instance, with reference to
step (e1) below.
[0081] As illustrated in FIGS. 7 and 8, first and second wing
portions (or "left" and "right" wings) (210 and 220, respectively),
which are initially provided in rib knit configuration, are
considerably separated by an initial separation distance (130 in
FIG. 7A and FIG. 7B). To successfully close the heel using a
knitting process, the wing portions (210, 220) must be moved closer
to one another (until a "knitting" separation distance is obtained,
which may be about 1 inch). The distance can be reduced by racking.
However, it is not possible to carry out a sufficiently large
racking with the needle beds (110A, 110B, 120A, 120B) tied on a rib
knit. Therefore, a series of stitch transfer and racking steps
according to a method described herein must be carried out to
permit successful closing of the heel. These steps are illustrated
schematically in FIGS. 7 and 8. However, for purposes of clarity
and emphasis, it should be noted that not every feature is
necessarily shown or labeled in each of the various portions of
FIGS. 7 and 8.
[0082] With reference to FIG. 7A, a first wing portion (210) can be
knittingly joined to a second wing portion (220) to form a heel
portion, as described herein. In addition, as in Example 1 above,
the wing portions (210, 220) in FIGS. 7 and 8 are illustrated
schematically to represent the edges of the wing portions (210,
220). Knitting the first wing portion (210) to the second wing
portion (220) to form the heel portion or "close the heel" is
carried out by (e1) transferring stitches (211) of the first edge
(210) from the back V needle bed (120A) to the front top needle bed
(110B) and transferring stitches (221) of the second edge (220)
from the front V needle bed (110A) to the back top needle bed
(120B) (FIG. 7B); (e2) racking the back needle bed(s) (120) to
reduce the lateral separation distance (130) between the first wing
portion (210) and the second wing portion (220) from the initial
separation distance (130 in FIG. 7A and FIG. 7B) to an intermediate
separation distance (130 in FIG. 7C); (e3) transferring the
stitches (211) of the first edge (210) from the front top needle
bed (110B) to the back V needle bed (120A) and from the front V
needle bed (110A) to the back top needle bed (120B), and
transferring the stitches (221) of the second edge (220) from the
back top needle bed (120B) to the front V needle bed (110A) and
from the back V needle bed (120A) to the front top needle bed
(110B) (FIG. 7D and FIG. 7E); and (e4) racking the back needle beds
(120) back to the position of step (e1) to reduce the lateral
separation (130) between the first wing portion (210) and the
second wing portion (220) from the intermediate separation distance
(130 in FIG. 7C) to a knitting separation distance (130 in FIG.
7F). As described above for a V-bed knitting machine, it is to be
noted that racking may also be carried out using the front needle
beds (110).
[0083] In addition, as with a method carried out using a V-bed
knitting machine, once a knitting separation distance (130) between
the wing portions (210, 220) is obtained, it is possible to carry
out additional knitting steps with the four-bed knitting machine
(100) to form a seamless knitted shoe component. As illustrated in
FIG. 7G, knitting the first wing portion (210) to the second wing
portion (220) further comprises (e5) transferring the stitches
(211) of the first edge (210) from the back top needle bed (120B)
to the front V needle bed (110A) and transferring the stitches
(221) of the second edge (220) from the front top needle bed (110B)
to the back V needle bed (120A). Next, knitting or forming a welt
(230) is carried out in a plurality of knitting steps (collectively
(e6)). Specifically, the welt (230) is formed by first (e6-1)
disposing a plurality of stitches in a rib knit configuration on
needles of the front needle beds (110) and the back needle beds
(120) within the gap defining the knitting separation distance of
the method, as illustrated in FIG. 8A. Next, to form a French welt,
the method illustrated in FIG. 8 comprises (e6-2) disposing or
knitting a plurality of stitches in a jersey knit configuration on
needles of the back needle bed(s) within the gap defining the
knitting separation distance (see FIG. 8B); and (e6-3) disposing or
knitting a plurality of stitches in a jersey knit configuration on
needles of the opposite needle bed(s) as in step (e6-2), the
needles being within the gap defining the knitting separation
distance (see FIG. 8C). It should be noted that, to form another
type of welt, such as an English welt or a racked welt, steps
(e6-2) and (e6-3) can be replaced by knitting steps corresponding
to these welt types, as understood by one of ordinary skill in the
art. Moreover, steps (e6-2) and (e6-3) (or the corresponding steps
for other welt types) can be repeated any desired number of times
to increase the thickness of the welt.
[0084] Following formation of the welt (230), the method further
comprises (e7) knitting at least one additional course on each of
the first edge (210) and the second edge (220) to reduce the number
of held stitches on each of the first edge (210) and the second
edge (220) by at least one stitch (FIG. 8D; held stitches not
shown); (e8) transferring the remaining held stitches (211) of the
first edge (210) from the back V needle bed (120A) to the front top
needle bed (110B) and transferring the remaining held stitches
(221) of the second edge (220) from the front V needle bed (110A)
to the back top needle bed (120B) (FIG. 8E); (e9) racking the back
needle beds (120) to reduce the lateral separation (130) between
the first wing portion (210) and the second wing portion (220)
(FIG. 8F); (e10) transferring the remaining held stitches of the
first edge (210) from the front top needle bed (110B) to the back V
needle bed (120A) and from the front V needle bed (110A) to the
back top needle bed (120B), and transferring the remaining held
stitches of the second edge (220) from the back top needle bed
(120B) to the front V needle bed (110A) and from the back V needle
bed (120A) to the front top needle bed (110B) (FIGS. 8G and 8H);
and (e11) racking the back needle beds (120) back to the position
of step (e7) (FIG. 8I). The position of step (e7), as illustrated
in FIG. 8, comprises a zero position of the needle beds (110, 120)
and/or the knitting machine (100). The method further comprises
(e12) transferring the remaining held stitches of the first edge
(210) from the back top needle bed (120B) to the front V needle bed
(110A) and transferring the remaining held stitches of the second
edge (220) from the front top needle bed (110B) to the back V
needle bed (120A) (FIG. 8J).
[0085] To complete formation of the heel portion, steps (e7)
through (e12) are repeated until substantially all of the stitches
of the first edge (210) and substantially all of the stitches of
the second edge (220) have been used to knittingly join the first
wing portion (210) to the second wing portion (220) to form the
heel portion.
EXAMPLE 3
Knitted Shoes and Shoe Components
[0086] Knitted shoes, shoe components, and fabrics used to form
such shoes and components according to some embodiments described
herein are illustrated in FIGS. 9-20. For example, FIG. 9
illustrates a portion of a knitted fabric (200) used to form a
knitted shoe component described herein. As illustrated in FIG. 9,
the first wing portion (210) and the second wing portion (220) of
the fabric (200) have not yet been knittingly joined at their edges
(212, 222) to form the heel portion of the knitted shoe component.
The fabric (200) also includes a previously knitted toe portion
(240).
[0087] FIGS. 10-13 illustrate different views of a finished knitted
shoe upper (200) described herein. Specifically, FIG. 10 is a top
view of the knitted shoe upper (200). As illustrated in FIG. 10,
the knitted shoe upper (200) includes a first wing portion (210)
that forms a medial side of the shoe upper (200); a second wing
portion (220) that forms a lateral side of the shoe upper (200); a
toe portion (240) knittingly connected to the first wing portion
(210) and the second wing portion (220); and a heel portion (250)
formed by the joining the first wing portion (210) and the second
wing portion (220), and knittingly connected to the first wing
portion (210) and the second wing portion (220). In addition, the
knitted shoe upper (200) of FIG. 10 also includes a tongue portion
(260). As described further hereinabove, the tongue portion (260)
can be sewn into a seamless knitted shoe component defined by the
first wing portion (210), the second wing portion (220), the toe
portion (240), and the heel portion (250). FIG. 11 is a perspective
view of the knitted shoe upper (200) of FIG. 10.
[0088] FIG. 12 is a perspective view of the knitted shoe upper
(200) of FIGS. 10 and 11. In particular, FIG. 12 illustrates an
insole portion (270) of the shoe upper (200). As depicted in FIG.
12, the insole portion (270) is highlighted for clarity. Moreover,
as described further hereinabove, the insole portion (270) is
knittingly and seamlessly connected to the heel portion (250) of
the shoe upper (200) at a knitted junction in a rear insole region
(271) of the shoe upper (200). In addition, the insole portion
(270) is joined to the first wing portion (210), the second wing
portion (220), and the toe portion (240) at a seam (272), which may
be formed by a sewing operation. FIG. 13 is a perspective view of
the heel portion (250) of the knitted shoe upper (200). As depicted
in FIG. 13, the heel portion (250) is highlighted for clarity.
[0089] As illustrated in FIGS. 10-13, the heel portion (250) of the
knitted shoe upper (200) has a relatively wide, rectangular
configuration. However, it is also possible for a heel portion
described herein to have other sizes and/or shapes. For example,
FIGS. 14-19 illustrate alternative configurations and structures
for the heel portion (250) of a knitted shoe component (200)
described herein. As illustrated in each of FIGS. 14-19, the heel
portion (250) is highlighted. FIGS. 14A, 15A, 16A, 17A, 18A, and
19A each illustrates a view of the back of the shoe component
(200), from the perspective of an observer looking toward the heel
portion (250). FIGS. 14B, 15B, 16B, 17B, 18B, and 19B illustrate
side views of the shoe components (200) of FIGS. 14A, 15A, 16A,
17A, 18A, and 19A, respectively. The arrow in FIG. 14B indicates
the direction of knitting during formation of the wing portions
(only the second wing portion (220) is visible in FIG. 14B).
[0090] Moreover, as described hereinabove, a knitted shoe component
such as a knitted shoe upper can have a variety of regions or zones
of the same or differing properties. As one non-limiting example,
FIG. 20 illustrates a knitted shoe upper (200) having regions of
higher breathability (achieved with a loose knit construction)
(201) and areas of lower breathability (achieved with a tight knit
construction) (202). The shoe upper (200) illustrated in FIG. 20
also includes stitch reinforced eyelets (280). Other configurations
of a knitted shoe upper are also possible.
[0091] Various embodiments of the present invention have been
described in fulfillment of the various objectives of the
invention. It should be recognized that these embodiments are
merely illustrative of the principles of the present invention.
Numerous modifications and adaptations thereof will be readily
apparent to those skilled in the art without departing from the
spirit and scope of the invention.
* * * * *